Roll Feeder
With variable feed speed, roll scrap is treated in a process-controlled manner. The virtually unmanned machine is fed continuously. The roll feeder can be operated at the same time with other types of feeding (e.g. conveyor belt).
NGR
In-House Film & Scrap Recycling
X:GRAN
The power package for plastic waste of all shapes and sizes
Overview
X:GRAN — high-output bulky waste recycling machine
A high-output shredder-feeder-extruder combination that sets new standards in throughput. The X:GRAN DCU processes large bales and carpet pads without pre-shredding — pieces need only fit the hopper opening.
← All NGR machinesAt a glance
- Easy, material-conserving processing, even for difficult industrial plastic waste
- Output rate up to 2,600 kg/h (5,730 lbs/h) depending on type
- Switching on and off by a single button
- Quick and easy start-up and shut-down at any time
- Small footprint saves space
How it works
The operating principle of X:GRAN
The Dynamic Classifying Unit (DCU) efficiently processes plastic waste with a powerful combination of a heavy-duty shredder, a hydraulic ram, and dual feed screws. The hydraulic ram precisely controls the material, holding it against the rotor, which gently reduces size using wear-resistant cutter teeth and precision-engineered dead blades.
The DCU effectively manages the size and density of the processed material with AUTO-PILOT, which integrates the shredder rotor, feed screws, and the load on the rotor—each controlled independently with dedicated drives.
Once shredded, the material is conveyed to the extruder via the dual feed screws. AUTO-PILOT manages the drives according to specific target settings. At the entrance of the extruder, a bespoke screw geometry ensures the production of high-quality material. This system is engineered for unparalleled mechanical robustness and reliability. The DCU stands out as the ideal solution for tackling the most challenging materials in plastic waste processing.
Key features
Why the X:GRAN
Bulky material processing
Handles large bales and carpet pads without pre-shredding for maximum throughput.
One-step technology
Slow-turning shredder blades grind the waste and the feeder screw feeds it continuously to the extruder.
Dump & run operation
Hopper level is measured constantly and the feed auto-regulates; one-button restart in under 2 minutes.
Automated control unit
The NGR touchscreen manages all functions with recipe management for traceability and correct parameters.
Universal extruder screws
Custom-developed for recycling to give optimum melt homogeneity with minimal property loss.
Uniform pellet size
High-quality, consistent pellets ensure homogeneous mixing into new material.
Technical data
Specifications
| Model | Extruder screw Ø (mm) | Shredder width (mm) | Max output (kg/h) | Max output (lbs/h) |
|---|---|---|---|---|
| X:GRAN 145-140 | 145 | 1,400 | 1,200 | 2,645 |
| X:GRAN 165-140 | 165 | 1,400 | 1,550 | 3,420 |
| X:GRAN 185-140 | 185 | 1,400 | 1,950 | 4,300 |
| X:GRAN 205-210 | 205 | 2,100 | 2,150 | 4,740 |
| X:GRAN 225-210 | 225 | 2,100 | 2,600 | 5,730 |
Options & accessories
Add-Ons
Conveyor belt
The conveyor belt transports the feed material through a metal detector into the feed hopper. The belt is stopped automatically, if metallic matter is detected in order to remove it.
Dosing unit
Additives such as color pigments, CaCo3, compatibilizers can be added to the material flow in a process-controlled manner. Dosing systems for pellet and/or powdered additives are available.
Single Venting
Designed for light printing and low humidity. The vacuum degassing system includes a vacuum pump and is connected to two venting ports on the extruder.
Double Venting
Designed for plastics printed, for example, on all surfaces and/or moist plastics. The simple venting unit can be supplemented by another modular unit with two venting openings and an additional vacuum pump.
Cascade
The cascade downstream of the melt filtration is equipped with a special degassing zone (Power Venting Section). This guarantees continuous renewal of the melt surface for removing volatile impurities from the melt for highest degassing requirements.
Vacuum pump with closed water circuit
Each venting combination can be equipped with a closed water circuit. The fresh water consumption at the vacuum pump is thereby reduced significantly.
High-performance vacuum
In addition to the modular venting unit, a combination of water ring pump and high-performance vacuum pump runs in order to increase the vacuum performance (e.g. PET processing).
Hot-die Waterring Pelletizer (HD)
For thermoplastics with a higher viscosity. The melt exits through the wear-resistant die plate, and is knocked off by the pelletizer blades. The pellets cooled in the water ring are flushed out, dried in the centrifuge and discharged. By adjusting the blade pressure, pelletizer blades provide a long service life; replacement is quick and easy.
Strand pelletizer (SP)
For low-viscosity melts. The melt emerges from strand nozzles, is cooled in a water bath, dried by means of a fan and cut to the desired length in the pelletizer. The result is cylindrical, dust-free pellets with excellent mixing properties.
Automatic strand pelletizer (A-SP)
In addition to the benefits of the SP, the A-SP option offers the added convenience of fully automated start-up. The strands are transported automatically by a water slide to the pelletizer, and the pellets are dried in a centrifuge.
Underwater pelletizer (UWP)
For difficult-to-process (e.g. sticky) polymers or thermoplastics with a very high melt flow index. The melt emerges from the die plate and is knocked off by the pelletizer blades. The whole process takes place under water. In the centrifuge, the pellets are separated from the process water and dried.
Double-piston screen changer
For light impurities. The hydraulically operated double-piston screen changer allows continuous filtration of the melt. This allows a screen change without process shutdown.
Back-flush screen changer
For heavily contaminated materials. The hydraulically operated double-piston screen changer filters the melt in a process-controlled and continuous manner. The integrated backwash device automatically cleans the screens. The number of back-flushes and the related service life of the screens depend on the degree of contamination of the material.
4K back-flush filtration
For heavily contaminated materials. In contrast to the standard backflush screen changer with 2 screen cavities, this system is equipped with 4 screen cavities. The double filtration surface with the same frame size results in a longer filter life.
Band melt filter
For high contamination at high throughput rates. With the lowest melt losses and low filter costs, fully automatic operation ensures excellent filtration results. It is used particularly for post-consumer plastics.
High-performance melt filter
The continuous melt filters in the ERF series are suitable for a wide range of moderate and highly contaminated polymers and provides a pressure constant operation, long screen lifes, very low melt losses and a compact design. By the permanently rotating filter drum foreign particles are being constantly and effectively removed, depending on the application ERF melt filters enables throughputs from 150 to 10,000 kg/h.
Film Manufacturing
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Pipe Manufacturing
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Flow scale
The throughput scale is integrated in the machine control system and displays the current production output in kg/h (lbs/hr). The data can be logged in a BDE system.
Gas control unit
This unit provides quality control by continuously measuring pellet density. Based on preset parameters, the unit determines whether to switch the gates to the second choice or to scrap when this value falls below a setpoint. Monitoring is inline and integrated continuously in the production process.
Online Viscometer
For continuous melt viscosity measurement. Melt is taken from the production extruder, the viscosity is measured, and then the melt is returned to the extruder. Based on the differential pressure across the capillary, the viscosity of the material (IV value, MVR) is determined by means of a stored recipe.
Materials & applications
What it processes
Suitable materials
PA, PC, PPS, ABS, EVA & blends
LDPE decorated film rolls
PE artificial grass
PP geotextiles & nonwovens
EPS foam blocks
PP woven sacks & raffia
PA/PP carpets & ropes
Applications
Post-industrial recycling (PIR)
Post-consumer recycling (PCR)
High-volume bulky-waste recovery
Gallery
Material samples the X:GRAN processes
Complete the line
Works well with
- Washing Line (Herbold) — Wash contaminated feed before pelletising.
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